Acrylic is a transparent and versatile material that can be used for various applications, such as signs, displays, furniture, and art. However, acrylic can also be challenging to machine, as it is prone to melting, chipping, and cracking. Therefore, choosing the right tool and setting the right parameters are crucial for achieving a smooth and clean cut.

One of the most suitable tools for milling acrylic is the single flute spiral milling cutter. This tool has one flute that spirals along the tool axis, creating a helical cutting edge. The single flute design reduces the friction and heat generation, which can prevent the acrylic from melting and sticking to the tool. The spiral shape also helps to eject the chips from the cutting zone, reducing the risk of recutting and clogging.

The single flute spiral milling cutter can be either upcut or downcut, depending on the direction of the flute. An upcut spiral milling cutter has a clockwise flute that lifts the chips upward, away from the workpiece. This can improve the chip evacuation and the cutting efficiency, but it can also cause the top edge of the acrylic to fray and splinter. A downcut spiral milling cutter has a counterclockwise flute that pushes the chips downward, toward the workpiece. This can create a cleaner and smoother top edge, but it can also compress the chips and increase the cutting resistance.

The choice of upcut or downcut depends on the thickness and quality of the acrylic, as well as the desired finish. Generally, an upcut spiral milling cutter is more suitable for thin and flexible acrylic sheets, as it can prevent them from bending and vibrating. A downcut spiral milling cutter is more suitable for thick and rigid acrylic sheets, as it can prevent them from lifting and cracking.

QT TOOLS also has upcut or downcut single flute spiral milling cutter for your choice.

The parameters of the single flute spiral milling cutter, such as the diameter, the speed, and the feed, also affect the quality and efficiency of the cut. The diameter of the tool determines the size and depth of the cut, as well as the strength and durability of the tool. Larger diameters can make wider and deeper cuts, but they also require more power and slower feed rates. Smaller diameters can make finer and shallower cuts, but they also have less rigidity and wear resistance.

The speed of the tool is the rate at which the tool rotates, measured in revolutions per minute (RPM). The speed affects the heat generation and the chip formation, which can influence the surface finish and the tool life. Higher speeds can reduce the heat and improve the chip breaking, but they can also increase the vibration and the tool wear. Lower speeds can reduce the vibration and the tool wear, but they can also increase the heat and the chip size.

The feed of the tool is the rate at which the tool advances along the workpiece, measured in millimeters per minute (mm/min) or millimeters per tooth (mm/tooth). The feed affects the material removal rate and the cutting force, which can influence the productivity and the accuracy. Higher feeds can increase the material removal rate and the cutting efficiency, but they can also increase the cutting force and the tool deflection. Lower feeds can reduce the cutting force and the tool deflection, but they can also reduce the material removal rate and the cutting efficiency.

The optimal parameters of the single flute spiral milling cutter depend on the type and size of the tool, the type and thickness of the acrylic, and the desired quality and speed of the cut. There are some general guidelines and formulas for calculating the parameters, but they may need to be adjusted based on the actual results and conditions. One of the sources that provides some useful information and examples is the STEPCRAFT Milling Calculator¹, which can be downloaded from the App Store or the Play Store.

By using the single flute spiral milling cutter and setting the appropriate parameters, you can mill acrylic with high precision and quality. You can also explore different types of cuts and designs with this versatile tool. If you have any more questions about the end mill, don’t hesitate to contact with QT TOOLS.

(1) Routing - ACRYLITE®. https://www.acrylite.co/resources/fabrication-manuals/routing-premium-acrylite-acrylic-sheet.

(2) The right cutting data. https://www.stepcraft-systems.com/en/services/milling-parameters.

(3) Acrylic Cutting Tools: 4 Strategies for Milling Acrylic. https://www.datron.com/resources/blog/acrylic-cutting-tools-4-strategies-for-milling-acrylic/.